Paper box



H. CARLE March 24, 1931.

PAPER BOX Original Filed Jan. 8, 1925 ATTORNEYS I m a Patented Mar. 24, 1931 UNITED STATES PATENT OFFICE HAROLD CARLE, OI BUFFALO, NEW YORK, ASSIGNOR TO" F. N. BURT COMPANY,

LIMITED, OF TORONTO, ONTARIO, CANADA, A CORPORATION OF ONTARIO, CANADA PAPER BOX Application filed January- 8, 1925, Serial No. 1,154. Renewed June 17, 1930.

This invention relates to boxes and methods of manufacturing the same, and with respect to its more specific features to the manufacture of a box base composed of paper and similar fragile material which, while adapted in its rough or partly finished condition to serve as a tray or container, is more especially designed to be further operated on and especially to be covered with ornamental material so as to produce a finished and durable papenbox, by a few simple operations and with economic use of paper.

One of the objects of the invention is the provision of a simple rectangular box base of the character referred to.

Another object of the invention is the provision of a practical and economic method of manufacturing a small relatively stiff, rectangular, paper box composed of relatively stiff body material covered with material of a finishing or ornamental character and one in which the faces of the finished box, especially the exterior faces, are smooth and even throughout, free from blisters, puckers, ridges and the like and in general free from blemish.

Other objects of the invention will in part be obvious and will in part appear hereinafter. 7

The invention accordingly comprises the several steps and the relation and order of one or more of such steps with respect to each of the others, and the article possessing the features, properties, and the relation of elements, which are exemplified in the following detailed disclosure, and the scope of the application of which will be indicated in the claims. 1

For a fuller understanding of the nature and objects of the invention reference should be had to the following detailed description taken in connection with the accompanying drawing, in which Figure 1 is a perspective view of the bodyblank-held on a mandrel or former,

Fig. 2 is a view similar to Fig. 1, after adhesive has been applied to the body-blank,

Fig. 3 is an edge view, diagrammatically illustrating a bulged cover-blank in proximity to the body-blank, in the operation of applying the cover-blank,

- Fig. 4 is a perspective view illustrating thefinishing strip has been turned over the edges as in Fig. 9,

Fig. 9 is a perspective view of the finished box, partly broken away to show interior construction, and b Figs. 10 and 11 are enlarged details of the It will facilitate the disclosure to first describe the box base, which forms an element of the invention, and which is designed to be utilized as a foundation to be finished 0r ornamented as may be desired. The hea d of the box base includes the head 1 of a cornercut, rectangular body-blank, and the flange of the box base includes t-heflaps 2, 3, 4 and 5 of the same blank, the flaps being integral with the head of the blank, and being folded on scored lines into positions at right angles to the head 1, and so that adjacent flaps closely adjoin each other at the corners of the rectangular element thus produced. Facing the outside of the head 1 is a soft, pliable corner-cut cover-blank having a central or head portion 6 which registers with the head 1 of the body-blank, certain integral portions, or flaps, of the cover-blank extending to provide marginal portions 7 of the coverblank which marginal portions are adhesively secured to the flaps 2, 3, 4 and 5 as indicated in Fig. 4. A stay strip 8 is adhesively secured directly to the exterior faces of the flaps of the body blank so as to secure the flaps together in their upstanding relation to the head 1, and thisstrip serves also as a filling strip and lies on said flaps outside the -outer edges of the cover-blank. The stay strip preferably closely abuts the outer edges of the cover-blank so that the joint therebetween is not marked. In this Wise the finishing strip 9, which surrounds the flange exteriorly and is adhesively attached both to the stay strip and to the cover strip and overlies the joint between these last two elements, will lie smoothly and evenly and present an exterior surface substantially free from. pronounced ridges which. otherwise might be causedby pressing the soft finishing paper at the joint between the stay strip and the outer edges of the cover-blank on the flange. To obviate the chance of spacing the stay strip and the edges of the coverblank at such distances from each other as would result in an irregular joint therebetween peripherally of the flange, the outer edges 40 of the cover-blank, where it lies on the flaps, are straight, these edges being in alignment with each other per pherally of the flange. The proximate edge 41 of the stay strip is also straight. Not only is the joint referred to made more uniform by utilizing straight edges of the covering material, but the automatic application of the stay strip and cover-blank in eifective positions is much facilitated as will appear further on. As illustrated in Figs. 6, 9, 10 and 11, the width of the finishing strip 9 is such that it extends from the bottom of the flange to and beyond the open end of the box base, so that its outer, extended portion 42 may be folded across the open edge of the flange and down into the box base where it may be pressed against the inner walls of the box base to form a completed box.

It will be observed that in the formation of the box base only two pieces of paper are required in addition to the body-blank,,and it will be further observed that the entire exterior surface of the head and flaps of the body-blank is covered by the cover-blank together with the stay strip, the latter covering all the-exterior surface of the flaps not covered by thecover blank. Consequently the structure provides for the most economic use of the paper material.

Coming now to the method of making the box base a flat, corner-cut, rectangular, bodyblank having the head 1 and the flaps 2, 3, 4 and 5, is illustrated in Fig.1. Tofacilitate folding of the flaps relative to'the rectangular head 1 on predetermined right lines, the blank is scored or slit so as to weaken the same along such lines, 10, on one face of the corner-cut blank. The corner-cut bodyrections at right angles to each ot blank is of relatively stifl, bendable paper, as for instance, cardboard, straw board, pasteboard, or the like. In Fig. t the cover sheet, or cover-blank is illustrated. The coverblank may be thinner than the body-blank and is of relatively soft, pliant paper and preferably has an exterior glaz ed or other ornamental surface. In the form illustrated the cover-blank is formed from a rectangular piece of paper having the corners cut away as indicated at 11, fora purpose hereinafter described.

For convenience in performing the pressing and folding operations and applying the stay strip and the finishing strip, a rectangular mandrel 12 may be employed, and the head 1 of the body-blank may be held on the outer end of the mandrel 12, as by suction, so that there are no mechanical parts to interfere with the proper folding and positioning of the materials. For gumming the coverblank to the body-blank any suitable adhesive may be employed, and is applied to the flaps of the body-blank and preferably also over the head 1 on that face of the body-blank havingthe scores 10, as illustrated by the broken lines in Fig. 2.

In applying the cover-blank, or cover sheet, to the body-blank, the cover sheet is first bulged, or curved, as indicated in Fig. 3, so that the convexity of the curve faces the flat body-blank, and thereafter the center of the bulged portion is first applied to the central gummed portion of the body-blank, the coverblank thereafter being progressively pressed into contact with the body-blank from the central portion outwardly until the cover blank lies evenly and smoothly across the head 1 and on the flaps 2, 3, 4 and 5 of the flat, unfolded body-blank, and adheres to the flaps, as illustrated in Fig. 4. Thereafter, while the adhesive is moist, the flaps 2, 3, 4 and 5, with the adhering cover-blank portions, are folded on lines coincident with the edges of the head 1 in directions tending to tauten the cover sheet over the head 1 between opposite flaps, the flaps of the body-blank being thus caused to assume the position they would occupy in .the flange of the box base to be formed. In the present embodiment the folding takes place on the weakened lines 10 which definitely mark out the edges of the head of the box base. By first adhesively attaching the cover-blank as hereinbefore de- I son of the ability of the cover sheet to slip on the moist adhesive surface of the bodyblank without detracting from eflicient tautening and stretching of said sheet. As the opposite flaps fold in opposite directions the cover sheet is tautened in each of 0 posite her and is;

7 face of the body-blank having already been may be employed. '30

broken by the scoring. I p

It is very desirable that the bottom of the box base shall be of predetermined shape; in the present instance that it shall be flat overall. To assist in maintaining'the flat condition of the bottom, the head 1 is pressed, es-

pecially adjacent its margin, so as to prevent outward, bulging distortion thereof during the folding of the flaps. To effect this pressing a presserplate 13 may be employed. This plate may be of substantially the same dimensions as the head of the body-blank and may be yieldingly pressedagainst the full area of the cover-blank directly opposite said head. By making the pressing face of this plate 13 flat and smooth, its pressure on the coverblank assists in giving a smooth and even surface to the cover-blank opposite the head 1 and causes the cover-blank to adhere to the head 1 of the body-blank. Forfolding the flapsh the folding plates "14 tially the same in width as the flaps of the body-blank. By moving them toward the mandrel they initiate the folding of the flaps, and also cooperate with the mandrel subsequently to squeeze the cover sheet material on the flaps so as to effect firm adherence between the cover material and the fla s after the folding of the flaps and the stretching, or tauntenin of the cover sheet have been effected.

Vhile the flaps and the covermaterial thereon are held folded, and preferably also while the head is pressed by the plate 13, the material 8 is applied exteriorly across the joints 15, between the adjacent folded flaps, and adhesively directly secured on the exterior faces of the flaps 2, 3, 4 and 5 inorder to join adjacent flaps to each other and permanently maintain the flaps in folded relation toform the flange. The stay strip is narrower thanthe upstanding length of the flange and has a straight edge41 which may lie close to and in abutting relation to the outer straight edges 40-.of the flaps of the cover-blank which are adhesively secured to the flaps of the body-blank. 'In this wise the stay strip 8 may be applied at a point on' the folded flaps ofthe body-blank and the mandrel withthe flaps held thereomrotated on an axis .passing through the center of the head 1, with the result'that the sta strip will be wound upon the exterior of the a s and its edge 41'will be symmetrical with an lie close to the straightouter edges of the cover-blank. While some little spacing is permissible betweentheinner edge of the stay stri and the outer edges of the cover-blank, it is preferredese plates are substan-- that thestay strip should closely abut the edges of the cover-blank and provide a filler which, as it were, raises the surface. of the body flaps to one flush with the surface of the flaps of the cover sheet, the stay stripcovering. substantially all ofthe exterior surfaces of the fla s of. the body-blank except that'cov-.

ered by t e cover sheet.

In many casesmillions ofboxes of the character herein referred to are required to be exactly thesame in dimension andflappearance. By assembling the cover blankand body-blank and foldingand staying the same as hereinbefore described, it is practically assured that the resultant box. bases formed from similar sized blanks, respectively, will themselves be of exactly the samedimension andappearance. The stay strip 8 'isapplied while the cover-blank and the 'body blank ar'e held adhesively assembled in folded relation, so that there is practically no chance for the folded parts to move from established rela It will be observed that the cover-blank is appliedto the head of the body-blank in such position that, at the corners of said head,

the edges of the cover-blank substantially register with said corners at the intersection of the side" edges of the cutouts 16 of the body-blank, and do not extendinto'the cut- .outs. In. this wise the exterior'of the head ofthe body-blank may be substantially completely covered by the cover-blank and the folding of the body-blank flaps accomplished so as to fold the cover material without gathering of the cover material at the corners.

It is to be understood that the term box base herein employed is intended to include box covers as well, the invention being equal- 'ly adapted for either.

Thus by the above described construction and operations are accom lished, among others, the objects hereinbef ere referred to.

Since certain changes in carrying out the above process, and certain modifications in the article which embody the invention may be made without departing from its scope, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as it lustrative and not in a limiting sense.

Having described my invention, what I.

claim. as new and desire to secure by Letters I Patent, is l 1. ,A- box base the head of which includes the head of a corner-cut rectangular b0dy-' blank and the flange of which includes the flaps of said body-blank integralwith the body-blank, said flapsclosely adjoining at the corners of the box base, each of said flaps having adhesively attached thereto on its exterior face a marginal portion of a soft, pliable cover-blank, which cover-blank faces the head of saidbody-blank and has integral por tions extending onto said flaps to provide said m'arginal portions, and a strip of stay material adhesively connected exteriorly direct ly to said flaps to connect them together, said itlripklying outside the edges of said cover- 2. A box base the head of which includes the head of a corner-cut rectangular bodyblank and the flange of which includes the flaps of said body-blank integral with the body-blank, said flaps closely adjoining at the corners of the box base, each ofsaid flaps having adhesively attached thereto on its exterior face a marginal portion of a soft, pliable cover-blank, which cover-blank faces the head ofsaid body-blank and has integral portions extending onto said flaps to provide said marginal portions, the outer edges of said cover-blank on said flaps being straight and in substantial alignment peripherally of the flange of the box base, and a strip of stay material adhesively connected exteriorly directly to said flaps to connect them together and lying outside the edges of said cover blank.

' 3. A box base the head of which includes the head of a corner-cut rectangular bodyblank and the flange of which includes the flaps of said body-blank integral with the body-blank, said flaps closely adjoining at the corners of the box base, each of said flaps having adhesively attached thereto on its exterior face a 'marginal portion of a soft, pliable cover-blank, which cover-blank faces the head of said body-blank and has integral portions extending onto said flaps to provide said marginal portions, the edges of said cover-blank, at the corners of said head, substantially registering with said corners and being free of gathers at said corners of the head, the outer edges of said cover-blank on said flaps being straight and in substantial alignment peripherally of the flange of the box base, and a strip of stay material adhesively connected exteriorly du'ectly to sa d flaps to connect them together, said strip lying outside the edges of said cover blank.

4. A box base the head of which includes the head of a corner-cut rectangular bodyblank and the flange of which includes the flaps of said body-blank integral with the body-blank, said flaps closely adjoining at the corners of the box base, each of said flaps having adhesively attached thereto on its exterior face a marginal portion of a soft. pli

able cover-blank, which cover-blank faces the head of said body-blank and has integral portions ext-ending onto said flaps to provide said marginal portions, the edges of said cover-blank, at the corners of said head, substantially registering with said corners and being free of gathers at said corners of the head, the outer edges of said cover-blank on said flaps being straight and in substantial alignment peripherally of the flange of the box base, and a strip of stay material adhesively connected exteriorly directly to said flaps to connect them together, said strip lying outside the edges of said cover-blank, and a finishing strip peripherally surrounding said flange, overlying the joint on the flange between said stay strip and the edges of said cover-blank and adhesively connected on said flanges both to said stay strip and said cover-blank.

5. A box base the head of which includes the head of a corner-cut rectangular bodyblank and ,the flange of which includes the flaps of said body-blank integral with the body-blank, said flaps closely adjoining at the corners of the box base, a soft, pliant, cornercut rectangular cover-blank the head of which registers and is adhesively connected with the head of said body-blank and the flaps of which extend closely transversely of the ends of the head of said body-blank onto and part way, only, of the length ofthe flaps of said body-blank, and are adhesively attached to the flaps of the body-blank, adjacent flaps of said body-blank being joined by a strip of stay material of the thickness of said cover-blank adhesively connected directly exteriorly to the flaps of the bodyblank without overlapping the cover-blank.

6. A box base the head of which includes the head of a corner-cut rectangular bodyblank and the flan e of which includes the flaps of said body blank integral with the body-blank, said flaps closely adjoining at the corners of the box base, a soft, pliant. corner-cut rectangular cover-blank the head of wh1ch reglsters and is adhesively connected with the head of said body-blank and the flaps of which extend closely transversely of the ends of the head of said body-blank onto and part wa only, of the length of the flaps of said Ody-blank, and are adhesively attached to the flaps of the body-blank. the outer edges of the flaps of the cover-blank belng in al gnment peripherally of the flange of the box base, the flaps of said body-blank being connected together by an integral strip of stay material, of the same thickness as the cover-blank, adhesively connected directly, exteriorly, to the flaps of the body blank without overlapping the flaps of the cover-blank, said stay material covering substantially all of the exterior face of the flaps of the body-blank not covered by the flaps of the cover-blank.

7. A box base the head of which includes the head of a corner-cut rectangular bod blank and the flange of which includes t e flaps of said body-blank integral with the body-blank, said flaps closely adjoining at,

the corners of the box base, a soft, pliant, corner-cut rectangular cover-blank the head of WhlCl'l registers and is adhesively connected with the head of said body-blank and the flaps of which extend closely transversel of the ends of the head of said bod -blan onto and part way, only, of the lengtli of the independent pieces of soft, pliant paper w ich memes flaps of said body-blank and are adhesively attached to the flaps of the body-blank, adjacent flaps of said body-blank being joined by a strip of stay material of the thickness of said cover-blank adhesively connected directl exteriorly to the flaps of the bodyblan and covering substantially all of the exterior face of said body-blank not covered by said cover-blank.

8. A box base the head of which includes the head of a corner-cut rectangular bodyblank and the flange of which includes the flaps of said body-blank integral with the body-blank, said flaps closely adjoining at the corners of the box base, and two independent pieces of soft, pliant paper which serve to cover substantially the entire exterior surface of the head and flaps of said body-blank, one of said pieces lying against and being adhesively attached to theexterior of the head and flaps of the bod blank and the other of said pieces being a hesively attached to said flaps without overlapping said cover-blank.

9. A box base the head of which includes the head of a.corner-cut rectangular bod blank and the flange of which includes t e flaps of said body-blank integral with the body blank, said flaps closely adjoining at the corners of the box base, and a pluralist of serve to cover the entire exterior surface of the head and flaps of said body-blank, the edges of said ieces abutting each other, one of said pieces eing a corner-cut cover blank the head of which is in registry with that of said body blank, said cover-blank being free of gathers at the corners of the box base, and the edge of the cover-blank substantially registerin with the corners of the head of said bod lank, said cover-blank being held in stretc ed condition across the head of said body-blank.

In testimony whereof I aflix my si avature.

' HAROLD 0' LE. 

